Doc. No.

:PFPL/PA/ENG/05
PRAVAT FABRICATORS PVT. LTD Issued In : 25.01.2025
Rev. No. : 00
PROCESS APPROACH ON FMEA Issue No. : 00
Page No. : 1 of 1

1.0 OBJECTIVE
To follow an analytical technique by the Design / Manufacturing team to assure that, to the extent possible, potential failure modes and their associated causes / mechanism
have been considered & addressed based on past experience & concern to the process development.
2.0 SCOPE
This W.I. identifies all potential product, process & customer related failure mode causes and control for Occurrence reduction by Detection.
3.0 PROCESS OWNER
Head (Eng.) is overall responsible for the implementation of this Process and coordinating with Cross Functional Team (CFT)
5.0 ACTIVITIES OF THE PROCESS & THEIR INTERACTIONS WITH OTHER PROCESSES Legend : Input Output
P for Procedure Wfor Work Instruction & for
F Format
CFT Leader CFT Customer / CR

Start F
Prepare the preliminary Get the Customer
Process Flow Diagram Input, Customer
PFPL/PFD/01 specific
requirments for
Discuss the Potential Failure Mode ( I.e. What can go wrong?) F
FMEA (Design /
for each & every flow, sub flow, activity & sub activity in the
Process)
process, considering every minute detail of the process.

P Note:
1. Use previous knowledge of the process, experience on similiary
Choose the CFT A
process, hunch & common sense as guiding tool for the
memebers who are
determination of What can go wrong?
sufficinetly trained in
2. Perform Quality Stand Down operation to know the type of
FMEA (Design /
problem that can be faced.
Process as
applicable ) activity.
If not trained trained
them as per
PFPL/PA/HR/01
For each steps discuss in CFT HOW
THIS COULD HAPPEN ? I.e. Potential Discuss for the possible results
causes of Failure. Consider views of IF THINGS WENT WRONG ?
all the members of any capacity. List Or Potential effects of
all the probable failures, insignificant of Failures?
their contribution Discuss IS THIS
CAUSE EASY TO
DETECT. OR How
easily this cause/ reson
can be detected ? .I.e.
DETECTION (D)
Annexure:02
Decide How frequently this Decide on the impact or
happens. I.e OCCURRENCE (O) severity of the this failure?
Annexure:01 (A& B) I.e. SEVERITY (S)
Annexure :03

Discuss all current process

controls used for the
DETECTION of potential failures.
Discuss all current process Note:Use
controls used for the Mistake Proofing , SPC, Gauging
PREVENTION of potential and other methods to increase
failures. the detection level.

Note: As per the FORD

FMEA Handbook.
1. RPN is a value
between 1 to 1000.
There is no thresold
value above which an
Calculate RISK PRIORITY NUMBER (RPN) action must be taken or
below which we are
RPN = S X O x D excused from
considering an action.
Note: Make action plan in case of any of the following. 2. Severity : Rankings
1. Highest Severity items. 2. Highest criticality (Severity X Occurence). 3. Highest RPN No. of "9" or "10" are
restricted to safety or
Action are recorded when completed, the revised Severity, Occurence and Detection coloumns are government regulated.
completed, even if the values did not change. 3. Occurence : The
criterion for ranking
While preparing PFMEA (EMDET/F/ENG/006) following criteria is taken into consideration. Occurence "1" is the
Critical Characteristic: If Severity is 9 or 10. Major Charecteristic : If Sev is 5 ~8 and Occurence is 4 probability of failure is
~ 10. remote: failure is
unlikely.
For more details refer AIAG FMEA Manual. 4. Detection: The
criterion for renking "1"
is that detection is
almost certain.

Re / Decide Recommended Actions by assigning

Responsibility and Target Date of completion for the high
Severity / Criticality / RPN

Periodically review for the actions decided and action taken. Revise the FMEA for
the implementated actions and calculate new RPN.
Track the FMEA's revision level. F

Note: P
1.Revise FMEA for incorporation of permanent corrective action identified from 8D.
Refer procedure SAR/PA/MR/05.
2. Review FMEA in case of any change idenfied by the user in Engineering Change
Request (ECR).

Target Severity / No
Criticality / RPN
Satisfactory ?

Yes

Further reduce the next highest Severity

/ Criticality / RPN and improve the P
process by employing continual
improvement technique till the process A
becomes stable.
Refer EMDET/PA/UH/04

PREPARED BY: AJIT KUMAR REVIEWED BY: GAUTAM GORAI APPROVED BY: D.ROY ISSUED BY: AJIT KUMAR